Pre-pour sleeve system

ABSTRACT

A pre-pour sleeve system having a sleeve body and a key that cooperate to form a void in a floor, wall, or other structure. The sleeve body includes a first termination end and a second termination end defining a gap therebetween, each termination end including a mating sleeve feature. The key includes at least one mating key feature adapted to mate with each mating sleeve feature of the body, said key further having a key body that fits into the gap of the sleeve body. In an engaged position, the key is mated with the sleeve body to form a substantially continuous shape, around which concrete or other material is poured. After the concrete sets, the key is disengaged from the sleeve body, allowing the sleeve body to compress and be removed from the floor and reclaimed.

FIELD OF INVENTION

The present invention relates to a device for forming a void in a floor and, more particularly, to a sleeve assembly that is installed prior to the pouring of concrete floor material.

BACKGROUND OF INVENTION

Due to the recent desire for buildings having open floor plans, the popularity of floor boxes and poke-thru devices has grown. Poke-thru devices provide access to data-ports, teleports and power sources and allow for reconfiguration of desks and other office equipment having access to the poke-thru devices.

Typically, the poke-thru devices are placed into holes that have been drilled into the walls or flooring, the latter of which is comprised of steel beams that are normally covered with a flooring support, such as corrugated steel decking or plywood, upon which concrete is poured. Drilling holes for poke-thrus, however, requires the expense of specialized laborers to drill the holes, can be disruptive to occupants of the building, and leaves behind dust and debris which must be removed. Furthermore, it is possible to inadvertently drill into structures buried within the concrete because the location of the holes cannot always be determined with precision.

Therefore, there is a need for an improved device and method of forming voids for poke-thrus and floor boxes.

SUMMARY OF THE INVENTION

According to the present invention, a pre-pour sleeve system includes a substantially cylindrical-shaped body and a key, which cooperate to form a sleeve that is placed upon a flooring support structure prior to pouring concrete. As the key is disengaged from the sleeve, the circumference of the body decreases and the body may be easily removed from the hardened concrete, forming a void for insertion of a poke-thru device or floor box.

In one embodiment of the present invention, the substantially cylindrical-shaped body is provided with positioning holes, which may be engaged with a plate or brackets to adjust the height on the bottom of the sleeve so that the bottom of the sleeve does not interfere with the flooring support structure underneath the flooring.

In another embodiment of the present invention, the pre-pour sleeve system further includes a cap, which cooperates with the body and the key to maintain the substantially cylindrical shape of the body. Furthermore, the cap prevents debris present above the pre-pour sleeve system from falling to lower levels of the building.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of one embodiment of a pre-pour sleeve system, including a plate and a sleeve having a body and a key, according to the present invention;

FIG. 2 is a side perspective view of the body of the sleeve of FIG. 1;

FIG. 3 is a top view of the body of the sleeve of FIG. 1;

FIG. 4 is a side perspective view of the key of the sleeve of FIG. 1;

FIG. 5 is a front perspective view of a poke-thru device inserted into a void remaining in concrete or other flooring material after removal of the sleeve of FIG. 1;

FIG. 6 is a front perspective view of the pre-pour sleeve system of FIG. 1 as preassembled;

FIG. 7 is a front perspective view of the pre-pour sleeve system of FIG. 1, in which the sleeve is installed upon corrugated steel decking;

FIG. 8 is a front perspective view of another embodiment according to the present invention;

FIG. 9 is a front perspective view of a further embodiment of a pre-pour sleeve system, including a sleeve having a body and a key, and further including a cap and at least one L-bracket, according to the present invention;

FIG. 10 is an enlarged, partially broken away, top view of the body and the key of the pre-pour system of FIG. 9, in which the key is engaged with the body;

FIG. 11 is an exploded front perspective view of the pre-pour system of FIG. 9 with corrugated steel decking;

FIG. 12 is a front perspective view of the pre-pour system of FIG. 9, in which the pre-pour sleeve system is installed upon corrugated steel decking; and

FIG. 13 is a side view of the pre-pour system of FIG. 9 in which the pre-pour system is installed upon plywood.

DETAILED DESCRIPTION OF EMBODIMENTS

Referring to FIG. 1, a pre-pour sleeve system 10 includes a sleeve 11 having a substantially cylindrical-shaped body 12 with at least one positioning hole 13 and a key 14. The body 12 of the sleeve 11 includes an upper portion 16 and a lower portion 18 defining a height 20. The body 12 also includes a first termination end 22 and a second termination end 24, each of which extends the height 20 of the body 12.

Referring to FIGS. 2 and 3, the termination ends 22, 24 of the body 12 include mating sleeve features 26 and are spaced apart by a gap 28. The gap 28 is adapted to receive the key 14, as shown in FIG. 4, which includes a pair of mating key features 30 that mate with the mating sleeve features 26 of the body 12. The key 14 also includes a key body 32 that fits into the gap 28. When the pre-pour sleeve system 10 is in an engaged position, i.e., the key 14 is positioned between the termination ends 22, 24 of the sleeve 11 such that the key body 32 fits within the gap 28 of the body 12 and the mating key features 30 engage the mating sleeve features 26 of the body 12, the sleeve 11 becomes a continuous substantially cylindrical sleeve, as best shown in FIGS. 6 and 7. When the key 14 is removed from the sleeve 11, the system 10 is in a disengaged position and the body 12 can be flexed inward to reduce its circumference.

In operation, as shown in FIG. 6, the sleeve 11 is pre-assembled prior to installation by inserting the key 14 between the termination ends 22, 24 of the body 12 such that the mating sleeve features 26 of the body 12 receive the mating key features 30 of the key 14 and the key body 32 of the key 14 fits into the gap 28. The pre-assembled sleeve 11 is substantially in the form of a continuous cylinder, as best shown in FIGS. 6 and 7.

The pre-assembled sleeve 11 is then passed through a plate 40 having at least one tab 42 and into a receiving hole 44 formed within a corrugated steel deck 46, which is supported by one or more steel beams 48, as shown in FIG. 6.

The position of the sleeve 11 relative to the plate 40 may be adjusted so that the sleeve 11 does not interfere with the support structure below the corrugated steel deck 46, for example, the steel beams 48, by selecting and lining up each desired positioning hole 13 of the body 12 with the at least one tab 42 on the plate 40. The desired configuration of positioning hole 13 and tab 42 may be fixed by inserting any suitable attachment means 50, such as, for example, a bolt, from an interior side 15 of sleeve 11 through the positioning hole 13 and tab 42, as shown in FIG. 7.

Referring to FIGS. 5 and 7, once the pre-pour sleeve system 10 is in place, concrete or other suitable flooring material 52 may be poured around the pre-pour sleeve system 10. After the concrete 52 sets and fully hardens, the key 14 is disengaged from the gap 28 in the body 12 by lifting the key upward or pushing it downward. The body 12 then becomes flexible and the circumference of the body 12 is effectively decreased, thereby allowing for easy removal of the body 12 from the hardened concrete flooring. The body 12 may be lifted upward and away from the concrete 52 and used again. A substantially straight-walled void 54 remains in the floor and a poke-thru device 56 or any other like device for providing an interface for voice, data, and fiber optic applications may be inserted into the void 54. Accordingly, the poke-thru device 56 is in contact with the concrete flooring 52 and no gaps are present.

Referring to FIG. 8, in another embodiment of the present invention, the key 114 is longer than the height 120 of the body 112 and protrudes upward therefrom to facilitate easier removal of the key. More specifically, the key 114 may be grasped, pulled upward, and disengaged from the body 112.

Referring to FIG. 9, according to another embodiment of the present invention, a pre-pour sleeve system 210 includes a sleeve 211 having a substantially cylindrical-shaped body 212 with at least one positioning hole 213 and a key 214, and optionally a cap 260 and at least one L-bracket 240 having a short portion 242, a long portion 243, and at least one bracket hole 241. The body 212 of sleeve 211 includes an upper portion 216 and a lower portion 218 defining a height 220. The body 212 also includes a first termination end 222 and a second termination end 224, each of which extends the height 220 of the body 212.

Referring to FIG. 10, the termination ends 222, 224 of the body 212 include mating sleeve features 226 and are spaced apart by a gap 228. The gap 228 is adapted to receive the key 214, which includes a pair of mating key features 230 that mate with the mating sleeve features 226 of the body 212. The key 214 also includes a key body 232 that fits into the gap 228 along an interior side 215 of the sleeve 211. When the pre-pour sleeve system 210 is in an engaged position, i.e., the key 214 is positioned between the termination ends 222, 224 of the body 212 such that the key body 232 fits within the gap 228 of the body 212 and the mating key features 230 of the key 214 mate with the mating sleeve features 226 of the body 212, the sleeve 211 becomes a substantially continuous cylinder, as best shown in FIGS. 9 and 11. When the key 214 is disengaged from the body 212, the body 212 can be flexed inward and compressed to reduce its circumference.

In operation, as shown in FIG. 11, the sleeve 211 is pre-assembled prior to installation by inserting the key 214 between the termination ends 222, 224 of the body 212 such that the mating sleeve features 226 of the body 212 mate with the mating key features 230 of the key 214 and the key body 232 of the key 214 fits into the gap 228 of the body 212. The pre-assembled sleeve 211 is substantially in the form of a continuous cylinder. Optionally, the cap 260 may be placed upon the upper portion 216 of the sleeve 211.

The pre-assembled sleeve 211 is then aligned with the at least one L-bracket 240. Either the short portion 242 or the long portion 243 of the L-bracket 240 may be placed in contact with the sleeve 211. As shown in FIG. 12, when mounting the pre-pour sleeve system 210 to corrugated steel decking 246, the short portion 242 of the L-bracket 240 is placed in contact with the sleeve 211 so that the long portion 243 extends outwardly therefrom. In this configuration, the lower portion 218 of the body 212 may be inserted into a receiving hole 244 of the corrugated steel decking 246 and the upper portion 216 of the body 212 remains exposed above the corrugated steel decking 246. As shown in FIG. 13, when the pre-pour sleeve system 210 is to be mounted to plywood 245, the long portion 243 of the L-bracket 240 is placed in contact with the sleeve 211 so that the lower portion 218 of the body 212 rests upon the plywood 245 and both the upper portion 216 and the lower portion 218 of the body 212 are exposed above the plywood 245.

Once the desired configuration of the L-bracket 240 relative to the sleeve 211 is achieved, the L-bracket 240 may be fixed to the sleeve 211 by passing at least one thumb screw 250 or other attachment means from the interior side 215 of the body 212, through the positioning hole 213 of the body 212, and through a bracket hole 241 in the L-bracket 240 and securing the thumb screw 250 by twisting a screw-back 252 onto the thumb screw 250 on an exterior side 217 of the body 212, as shown in FIGS. 11-13.

To install the sleeve 211, the lower portion 218 of the body 212 is then either inserted into a receiving hole 244 formed within a corrugated steel deck 246, as shown in FIG. 12, or rested upon and fixed to the plywood 245, as shown in FIG. 13.

Referring to FIG. 14, once the pre-pour sleeve system 210 is in place, concrete or other suitable flooring material 252 may be poured around the pre-pour sleeve system 210. After the concrete 252 sets and fully hardens, the cap 260 is removed and the at least one thumb screw 250 is removed. The key 214 is then disengaged from the body 212 by pulling the key 214 upward or pushing the key 214 down through the body 212. The body 212 then becomes flexible and the circumference of the body 212 is effectively decreased, thereby allowing for easy removal of the body 212 from the hardened concrete flooring 252. The body 212 and key 214 may be reclaimed and used again. As shown in FIG. 5, a substantially straight-walled void 54 remains in the floor and a poke-thru device 56 or any other like device for providing an interface for voice, data, and fiber optic applications is inserted into the void 54. Accordingly, the poke-thru device 56 is in contact with the concrete flooring 52 and no gaps are present.

The body 12, 112, 212 can be fabricated from metal, such as aluminum, plastic, such as acrylonitrile-butadiene-styrene (ABS). In the preferred embodiment, the body is fabricated from poly vinyl chloride (PVC). It will be appreciated by those of ordinary skill in the art, however, that any material that does not adhere to concrete and has at least slight springing characteristics may be employed. Likewise, the key 14, 114, 214 can be fabricated from metal, plastic or any material having rigid properties that may easily be disengaged from the body 12, 112, 212.

The present invention provides many advantages over existing methods and devices for forming voids suitable to receive poke-thru devices and similar devices. For example, drilling to form voids in concrete requires specialized laborers, who must often be brought onto a job site solely for the purpose of drilling to form voids. This labor-intensive work is expensive and time consuming. The present invention eliminates the need for specialized laborers, thereby decreasing expenses, saving time, and increasing efficiency of new construction.

Another advantage of the present invention is its ability to be removed from hardened concrete flooring and be reclaimed and reused. More specifically, the sleeve 11, 111, 211 features a removable key 14, 114, 214 which, when removed, effectively decreases the circumference of the body 12, 112, 212 so that the body, which is flexible once the key is disengaged, may be flexed inward and lifted from the hardened concrete 52 or other flooring material. Furthermore, from an environmental perspective, it is advantageous to reclaim and reuse the sleeve 11, 111, 211 to decrease the amount of waste produced in the formation of voids for poke-thru devices. Also, the present invention eliminates waste and debris generated by removed concrete.

Another advantage of the present invention over existing devices is that the present invention features substantially straight walls to form a void having substantially straight walls. Although tapered walls could potentially be used to form a void also having tapered walls, a void having tapered walls would not be suitable for receiving a poke-thru device that-has straight walls.

Another advantage of the present invention over existing devices is the ability to select and adjust the height of the sleeve relative to the flooring support structure. This ability to select height allows for the device to remain above the level of the flooring without interfering with or damaging the support structure, for example, the steel beams, beneath. Furthermore, the portions of the body that extend above the flooring prevent concrete from flowing on top of or through the pre-pour sleeve system. Similarly, if the cap 260 is employed, the cap 260 will prevent concrete from flowing into the sleeve 11, 111, 211, and will prevent any debris from falling through the flooring. The cap also helps maintain the rigid substantially cylindrical shape of the sleeve when the key and body are engaged. Since the key is easily accessible from above the floor, no special tools or devices are required to disengage the key in an upward direction or a downward direction and remove the sleeve from above the flooring.

Another major advantage of the present invention is the ability for architects and builders to plan in advance the location of the voids. Unlike drilling methods, in which the location of the holes cannot be precisely pre-planned, the present invention forms predictable voids into-which a poke-thru device may be securely placed. Furthermore, as will be appreciated of those skilled in the art, concrete flooring often includes steel rods and cables running through the concrete substrate. Thus, another advantage of the present invention is the predictability of the location of the voids and, accordingly, the prevention of inadvertently drilling or cutting through those steel rods and cables.

The present invention also includes safety advantages. For example, the present invention does not leave behind a cardboard body or other fire-hazardous material in the floor. Similarly, there is some inherent danger associated with drilling, the need for which is eliminated by the present invention.

While the present invention has been illustrated and described with respect to particular embodiments thereof, it will be appreciated by those skilled in the art that various modifications to this invention may be made without departing from the spirit and scope of the present invention. For example, while the present invention has been described as fabricated from metal and plastics, any materials that have the desirable characteristics may be employed. Moreover, the sleeve of the present invention has been described as a substantially cylindrical shape, however, the sleeve could be any suitable shape. Similarly, the termination ends of the present invention have been described as extending the height of the body, however, the termination ends could extend beyond the height of the body or could extend over a partial height of the body. In addition, the L-brackets and plate have been described as structures for securing the sleeve to a flooring support structure and adjusting the height of the sleeve relative to the flooring support structure. It will be appreciated, however, that any securing means could be employed. Furthermore, although the present invention has been discussed primarily with respect to placement in a floor structure, it will be appreciated by those skilled in the art that the present invention could be used in a wall or a fire-safety wall. More specifically, the present invention may be used to form a void into which cables and wiring could be passed through, while maintaining the fire safety rating of the wall or floor. 

1. A pre-pour sleeve system comprising: a sleeve body; and a key adapted to cooperate with the sleeve body to form a void.
 2. The system of claim 1, wherein the sleeve body includes a first termination end and a second termination end.
 3. The system of claim 2, wherein the key in an engaged position mates with the first termination end and the second termination end of the sleeve body to form a substantially continuous, substantially cylindrical sleeve.
 4. The system of claim 2, wherein the key in a disengaged position does not mate with the first termination end and the second termination end of the sleeve body and allows for the sleeve body to compress.
 5. The system of claim 1, further comprising a cap.
 6. The system of claim 1, further comprising a securing means for attaching the sleeve to a flooring support surface.
 7. The system of claim 6, further comprising a plurality of positioning holes allowing for height adjustment of the sleeve relative to the securing means.
 8. A pre-pour system comprising: a sleeve body including a first termination end and a second termination end to define a gap therebetween, the first termination end and the second termination end each including a mating sleeve feature; and a key including a key body adapted to fit into the gap of the sleeve body and at least one mating key feature adapted to mate with the mating sleeve features of the first termination end and the second termination end of the sleeve body.
 9. The system of claim 8, wherein the mating key features are mated with the mating sleeve features of the first and second termination ends of the sleeve body to form a substantially continuous, substantially cylindrical sleeve suitable for forming a void.
 10. The system of claim 8, wherein the key may be disengaged from the sleeve body to allow for compression of the sleeve body for easy removal of the sleeve body from a floor.
 11. The system of claim 8, further comprising a plate having an aperture adapted to receive the sleeve and having at least one tab adapted to align with at least one positioning hole formed in the sleeve body, wherein a height of the sleeve body relative to the plate may be adjusted, and wherein the height of the sleeve body relative to the plate may be fixed by an attachment means inserted through the at least one tab of the plate and through the at least one positioning hole formed in the sleeve body.
 12. The system of claim 8, further comprising at least one L-bracket adapted to align with at least one positioning hole formed in the sleeve body, wherein a height of the sleeve body relative to the at least one L-bracket may be adjusted, and wherein the height of the sleeve body relative to the at least one L-bracket may be fixed by an attachment means inserted through the at least one L-bracket and through the at least one positioning hole formed in the sleeve body.
 13. The system of claim 12, further comprising a cap adapted to be secured to the sleeve.
 14. A method of forming a void in a floor comprising: providing a sleeve system having a sleeve body and a key inserted therein; positioning the sleeve system onto a support surface; forming a floor around the sleeve system; and removing the key in order to compress the sleeve body.
 15. The method of claim 14, further comprising reclaiming the sleeve body after removing the key.
 16. The method of claim 14, further comprising inserting the sleeve system into an aperture of a plate prior to positioning the sleeve system onto the support surface.
 17. The method of claim 16, further comprising selecting a height of the sleeve system relative to the support surface by inserting at least one attachment means through at least one positioning hole formed in the sleeve body and through at least one tab provided in the plate.
 18. The method of claim 14, further comprising fixing the sleeve system to at least one L-bracket prior to positioning the sleeve system onto the support surface.
 19. The method of claim 18, further comprising selecting a height of the sleeve system relative to the support surface by inserting at least one attachment means through at least one positioning hole formed in the sleeve body and through at least one hole provided in the at least one L-bracket.
 20. The method of claim 19, further comprising placing a cap onto the sleeve system prior to forming a floor around the sleeve system. 